U.S. patent number 10,883,743 [Application Number 16/054,431] was granted by the patent office on 2021-01-05 for water heater with flow bypass.
This patent grant is currently assigned to Rheem Manufacturing Company. The grantee listed for this patent is Rheem Manufacturing Company. Invention is credited to Jozef Boros.
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United States Patent |
10,883,743 |
Boros |
January 5, 2021 |
Water heater with flow bypass
Abstract
A water heater has a water supply line, a heat exchanger in
fluid communication with the water supply line, a heating element
positioned proximate to the heat exchanger, such that when
activated, the heating element conveys heat to the heat exchanger
and thereby heating water supplied by the water supply line, an
output line in fluid communication with the heat exchanger and
configured to receive heated water therefrom, a flow sensor
configured to cause the heating element to activate in response to
sensing a predetermined water flow rate through the water heater,
and a bypass flow line operably connected between the water supply
line and the output line.
Inventors: |
Boros; Jozef (Montgomery,
AL) |
Applicant: |
Name |
City |
State |
Country |
Type |
Rheem Manufacturing Company |
Atlanta |
GA |
US |
|
|
Assignee: |
Rheem Manufacturing Company
(Atlanta, GA)
|
Family
ID: |
1000005282278 |
Appl.
No.: |
16/054,431 |
Filed: |
August 3, 2018 |
Prior Publication Data
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|
|
Document
Identifier |
Publication Date |
|
US 20190041095 A1 |
Feb 7, 2019 |
|
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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62541037 |
Aug 3, 2017 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24H
9/1836 (20130101); F24H 9/0005 (20130101); F24H
9/128 (20130101); F24D 19/1051 (20130101); F24H
9/2035 (20130101); F24H 1/107 (20130101); F24H
9/142 (20130101); F24D 2220/044 (20130101); F24H
2210/00 (20130101) |
Current International
Class: |
F24H
1/18 (20060101); F24H 9/12 (20060101); F24H
9/20 (20060101); F24H 1/10 (20060101); F24H
9/18 (20060101); F24H 9/14 (20060101); F24H
9/00 (20060101); F24D 19/10 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Wilson; Gregory A
Attorney, Agent or Firm: Troutman Pepper Hamilton Sanders
LLP
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority to U.S. Provisional Patent
Application No. 62/541,037 filed Aug. 3, 2017 and titled "Water
Heater With Flow Bypass," the entire contents of which are
incorporated herein by reference.
Claims
What is claimed is:
1. A water heater comprising: (a) a heat exchanger in fluid
communication with a water supply line; (b) a heating element
positioned proximate to the heat exchanger, so that, when
activated, the heating element conveys heat to the heat exchanger,
thereby heating water supplied to the heat exchanger by the water
supply line; (c) an output line in fluid communication with the
heat exchanger and configured to receive heated water therefrom;
(d) a water flow sensor in operative communication with water flow
to or in the water heater to detect water flow from the water
supply line to the water heater and in operative communication with
the heating element to cause the heating element to activate in
response to detection of a predetermined water flow rate by the
water flow sensor; (e) a bypass water flow line operably connected
between the water supply line and the output line; (f) a pressure
sensor in operative communication with the water supply line to
detect a pressure of water in the water supply line; (g) a valve in
operative communication with the bypass water flow line so that
operation of the valve controls water flow in the bypass water flow
line; and (h) process circuitry configured to receive pressure data
indicative of the pressure of water in the water supply line and
cause the valve to open in response to the pressure of water in the
water supply line being below a predetermined pressure
threshold.
2. The water heater of claim 1 wherein the process circuitry is
further configured to: (a) receive a flow signal from the flow
sensor, and (b) cause the heating element to activate in response
to the flow signal indicating that the water flow through the water
heater satisfies the predetermined water flow rate.
3. The water heater of claim 1, wherein the processing circuitry is
further configured to: (a) receive temperature data from a
temperature sensor in operative communication with the output line,
to detect a temperature of water flow therethrough, and (b) control
a heat output of the heating element based on the temperature
data.
4. The water heater of claim 1, wherein the water flow sensor is
disposed in the water supply line.
5. The water heater of claim 4, wherein the bypass water flow line
is operably coupled to the water supply line downstream of the flow
sensor.
6. The water heater of claim 1, wherein the bypass water flow line
is disposed with respect to the water supply line and the heat
exchanger so that when water flows into the water heater from the
water supply line, the bypass water flow line reduces resistance to
flow between the water supply line and the output line.
7. A water heater comprising: (a) a heat exchanger in fluid
communication with a water supply line; (b) a heating element
positioned proximate to the heat exchanger so that, when activated,
the heating element conveys heat to the heat exchanger, thereby
heating water supplied to the heat exchanger by the water supply
line; (c) an output line in fluid communication with the heat
exchanger and configured to receive heated water therefrom, wherein
the output line comprises a storage vessel configured to store a
volume of the heated water; (d) a water flow sensor in operative
communication with water flow to or in the water heater to detect
water flow from the water supply line to the water heater and in
operative communication with the heating element to cause the
heating element to activate in response to sensing a predetermined
water flow rate by the water flow sensor; and (e) a bypass water
flow line operably connected between the water supply line and the
output line.
8. The water heater of claim 7, wherein the bypass flow line is
fluidly connected between the water supply line and the storage
vessel.
9. The water heater of claim 7 further comprising: processing
circuitry configured to: (a) receive a flow signal from the flow
sensor, and (b) cause the heating element to activate in response
to the flow signal indicating that the water flow through the water
heater satisfies the predetermined water flow rate.
10. The water heater of claim 9, wherein the processing circuitry
is further configured to: (a) receive temperature data from a
temperature sensor in operative communication with the output line
to detect temperature of water flow therethrough, and control a
heat output of the heating element based on the temperature
data.
11. The water heater of claim 9 further comprising: (a) a valve in
operative communication with the bypass flow line so that operation
of the valve controls flow of water in the bypass flow line.
12. The water heater of claim 11 further comprising: (a) a pressure
sensor in operative communication with the water supply line to
detect pressure of water in the water supply line, and (b) wherein
the processing circuitry is further configured to receive pressure
data indicative of the pressure of water in the water supply line
and cause the valve to open in response to the water supply line
pressure being below a predetermined pressure threshold.
13. The water heater of claim 7, wherein the flow sensor is
disposed in the water supply line.
14. The water heater of claim 13, wherein the bypass flow line is
operably coupled to the water supply line downstream of the flow
sensor.
15. The water heater of claim 7, wherein the bypass flow line is
disposed with respect to the water supply line and the heat
exchanger so that when water flows into the water heater from the
water supply line, the bypass flow line reduces resistance to flow
between the water supply line and the output line.
16. The water heater of claim 7, wherein the bypass flow line is
operably coupled to the output line downstream of the storage
vessel.
17. The water heater of claim 7, wherein the storage vessel is
thermally insulated.
Description
FIELD OF THE INVENTION
The present invention generally relates to a water heater and more
particularly relates to a water heater with a flow bypass.
BACKGROUND OF THE INVENTION
Hot water heaters are used to heat and store a quantity of water in
a storage tank for subsequent on-demand delivery to plumbing
fixtures such as sinks, bathtubs, showers, and appliances in
residential and commercial buildings. A typical demand based water
heater uses a combustible fuel gas, such as methane (i.e. natural
gas), wherein a gas burner disposed in a combustion chamber below a
heat exchanger burns the gas with ambient air, thereby heating the
water with a combination of heat radiated from the burner and heat
conducted from hot gaseous products of combustion (hereinafter,
"combustion gasses") traveling through the walls of the combustion
chamber and through the heat exchanger. The combustion gasses
travel from the combustion chamber, through the heat exchanger and,
ultimately, vent outside of the building or other enclosure in
which the tank is disposed.
Tankless water heaters eliminate the need for storing volumes of
hot water by heating water on demand. Other demand based water
heaters may include high recovery water heaters. High recovery
water heaters may be similar to tankless water heaters, but include
a relatively small storage vessel that receives a volume, such as 5
liters to 9 liters, of heated water from the heat exchanger. The
storage vessel may reduce variation in the outlet temperature of
the heat exchanger by allowing for mixing of the water exiting the
heat exchanger with the water in the storage vessel. Additionally,
the heated water in the storage vessel may provide heated water to
supply the demand while the heat exchanger of the water heater is
warmed to operating temperature.
On-demand water heaters typically include one or more flow
switches, which may sense flow through the water heater indicating
a demand for heated water. The flow switch may be configured to
indicate a demand in response to sensing a flow rate greater than a
predetermined flow rate threshold. In response to a signal from the
flow switch, the water heater actuates a gas burner to heat the
water that is now flowing through the water heater. However, the
flow rate through the water heater may vary in response to
variation in supply pressure of the local water supply. In some
instances, a low pressure condition may cause the flow rate through
the water heater to remain below the predetermined flow rate value
at which the flow switch is configured to indicate a demand,
thereby precluding the flow switch from sending a signal to the
water heater controller to activate the burner. Thus, it is
possible in such circumstances that a user may actuate an
appliance, so that heated water is needed, but the water heater
fails to actuate the burner because the low input water pressure
prevents flow from reaching the switch's trigger level.
SUMMARY OF THE INVENTION
The present invention recognizes and addresses considerations of
prior art constructions and methods.
In an example embodiment, a water heater has a water supply line, a
heat exchanger in fluid communication with the water supply line,
and a heating element positioned proximate to the heat exchanger so
that, when activated, the heating element conveys heat to the heat
exchanger, thereby heating water supplied to the heat exchanger by
the water supply line. An output line is in fluid communication
with the heat exchanger and configured to receive heated water
therefrom. A water flow sensor is in operative communication with
water flow to or in the water heater to detect water flow from the
water supply line to the water heater and in operative
communication with the heating element to cause the heating element
to activate in response to detection of a predetermined water flow
rate by the water flow sensor. A bypass water flow line is operably
connected between the water supply line and the output line.
In another example embodiment, a water heater has a water supply
line, a heat exchanger in fluid communication with the water supply
line, and a heating element positioned proximate to the heat
exchanger so that, when activated, the heating element conveys heat
to the heat exchanger, thereby heating water supplied to the heat
exchanger by the water supply line. An output line is in fluid
communication with the heat exchanger and configured to receive
heated water therefrom. The outlet line comprises a storage vessel
configured to store a volume of the heated water. A water flow
sensor is in operative communication with water flow to or in the
water heater to detect water flow from the water supply line to the
water heater and in operative communication with the heating
element to cause the heating element to activate in response to
sensing a predetermined water flow rate by the water flow sensor. A
bypass water flow line is operably connected between the water
supply line and the output line.
The bypass flow line may be a low resistance flow path around the
heat exchanger. The low resistance flow path may enable the flow
rate sensed by the flow sensor to be greater than it otherwise
would be, in absence of the bypass flow path, to thereby increase
the likelihood that water flow under low pressure conditions will
reach or exceed the predetermined flow rate threshold indicative of
a demand for heated water. In some example embodiments, a bypass
valve may be disposed in the bypass flow line that is configured to
open in response to a low pressure condition, e.g. a pressure less
than a predetermined pressure threshold, sensed at a water supply
line, e.g. a cold water inlet, and to close in response to the
pressure of the water supply line above the low pressure threshold.
The bypass valve may limit flow in the bypass flow line to low
pressure conditions, thereby maximizing flow through the heat
exchanger in the absence of a low pressure condition.
Further areas of applicability of the present invention will become
apparent from the detailed description provided hereinafter. It
should be understood that the detailed description and specific
examples, while indicating the preferred embodiments of the
invention, are intended for purposes of illustration only and are
not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
A full and enabling disclosure of the present invention, including
the best mode thereof, directed to one of ordinary skill in the
art, is set forth in the specification, which makes reference to
the appended drawings, in which:
FIG. 1 is a schematic view of a tankless water heater with a bypass
flow line according to an example embodiment;
FIG. 2 is a schematic view of a tankless water heater with a bypass
valve in a bypass flow line according to an example embodiment;
Each of FIGS. 3 and 4 is a schematic view of a tankless water
heater including a storage vessel and a bypass flow line according
to an example embodiment;
FIG. 5 is a schematic view of a tankless water heater including a
storage vessel with a bypass valve in a bypass flow line according
to an example embodiment;
FIG. 6 is a block diagram of one example of a controller according
to an embodiment for use with a tankless water heater as in FIGS.
1-5; and
FIG. 7 is a flow diagram of methods of controlling tankless water
heaters as in FIG. 1-5.
Repeat use of reference characters in the present specification and
drawings is intended to represent same or analogous features or
elements of the invention according to the disclosure.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Reference will now be made in detail to embodiments of the
invention, one or more examples of which are illustrated in the
accompanying drawings. Each example is provided by way of
explanation, not limitation, of the invention. In fact, it will be
apparent to those skilled in the art that modifications and
variations can be made in the present invention without departing
from the scope and spirit thereof. For instance, features
illustrated or described as part of one embodiment may be used in
another embodiment to yield a still further embodiment. Thus, it is
intended that the present invention covers such modifications and
variations as come within the scope of the appended claims and
their equivalents.
As used herein, terms referring to a direction or a position
relative to the orientation of the fuel-fired heating appliance,
such as but not limited to "vertical," "horizontal," "upper,"
"lower," "above," or "below," refer to directions and relative
positions with respect to the appliance's orientation in its normal
intended operation, as indicated in the Figures herein. Thus, for
instance, the terms "vertical" and "upper" refer to the vertical
direction and relative upper position in the perspectives of the
Figures and should be understood in that context, even with respect
to an appliance that may be disposed in a different orientation. As
used herein, operable coupling should be understood to relate to
direct or indirect connection that, in either case, enables
functional interconnection of components that are operably coupled
to each other.
Further, the term "or" as used in this disclosure and the appended
claims is intended to mean an inclusive "or" rather than an
exclusive "or." That is, unless specified otherwise, or clear from
the context, the phrase "X employs A or B" is intended to mean any
of the natural inclusive permutations. That is, the phrase "X
employs A or B" is satisfied by any of the following instances: X
employs A; X employs B; or X employs both A and B. In addition, the
articles "a" and "an" as used in this application and the appended
claims should generally be construed to mean "one or more" unless
specified otherwise or clear from the context to be directed to a
singular form. Throughout the specification and claims, the
following terms take at least the meanings explicitly associated
herein, unless the context dictates otherwise. The meanings
identified below do not necessarily limit the terms, but merely
provided illustrative examples for the terms. The meaning of "a,"
"an," and "the" may include plural references, and the meaning of
"in" may include "in" and "on." The phrase "in one embodiment," as
used herein does not necessarily refer to the same embodiment,
although it may.
Example Water Heater
FIGS. 1 and 2 illustrate a water heater 100 including a cold water
flow bypass path 122. The depicted water heater 100 of FIGS. 1 and
2 may or may not include a storage tank (as discussed in more
detail below) but does include a heat exchanger having sufficient
heat transfer capability to heat water flowing through the water
heater to a predetermined temperature (set point) as the water
flows through the heat exchanger, without need of a storage tank at
which to deliver heat to the water. Such water heaters may be
referred to as being "tankless," "instantaneous," or "on-demand."
Water heater 100 may include a water supply line 102, which may be
connected to a water source, such as a municipal cold water supply.
Water heater 100 may include a hot water outlet 104 connected
downstream to one or more plumbing fixtures, such as sinks,
showers, tubs, or the like, so that water heater 100 provides hot
water to the fixtures via outlet 104.
Water heater 100 includes a heating element, such as a fuel-fired
burner, 106. While the heating element is described as a fuel-fired
burner heating element, one of ordinary skill in the art should
appreciate that electric resistance heating elements may be used in
addition or alternatively. Burner 106 may be configured to burn
methane or other combustible fuel and may be operably coupled to a
fuel control valve 114 configured to supply or prevent the flow of
fuel from a fuel source line 112 to burner 106. Fuel source line
112 may be operably coupled to a fuel source, such as a residential
or commercial natural gas line. Burner 106 may produce heat by
combustion and be disposed proximate, such as beneath, a heat
exchanger 110. Heat and combustion exhaust generated by burner 106
may travel upward, due to thermal circulation and vent paths,
through heat exchanger 110 and a flue 118 and exit water heater 100
through an exhaust port 120. Exhaust port 120 may be operably
coupled to vent ducting (not shown) to vent the exhaust external to
a building, such as when the water heater 100 is disposed
internally to a building.
A portion 108 of the water input line may be operably coupled
between cold water supply line 102 and the heat exchanger and wrap
about burner 106 so that radiating heat from burner 106 transfers
to warming line portion 108 and, by transferring through the water
line walls, warms the water flowing therein. As a result, while
warming line 108 is described herein as a part of water input line
102, it may also be considered part of heat exchanger 110. Heat
exchanger 110 may include an input port that receives water from
water line 108 and that opens into a manifold that distributes the
cold water to a plurality of fluid flow paths, e.g. tubes, plates,
plate fins, or other conduits within heat exchanger 110 that
connect, at their opposite ends, to an output manifold that
connects to an output port to which hot water outlet line 104 is
fluidly connected. Within the heat exchanger, the hot exhaust gas
generated by burner 106 flows over the plurality of conduits (i.e.
the heater exchanger housing and the plurality of water conduits
form therebetween a flow path for the exhaust gas), transferring
heat from the exhaust gas to the water flowing through the
conduits. The water conduits may be formed from aluminum or other
material with a high heat transfer coefficient. In some example
embodiments, the water conduits of heat exchanger 110 may be
configured to provide a torturous path for exhaust flow, including
cross flow and back flow, to increase the heat exchanger's area
available to receive heat from the exhaust gas to the water,
thereby increasing the amount of heat transfer to the water. The
torturous path through heat exchanger 110 may be formed from
straight fins, offset fins, wavy fins, or the like and, as
discussed above, establishes a sufficient surface area for heat
transfer between the flowing exhaust gas and the flowing water that
the heat exchanger warms the water to a desired temperature (set
point) range as the water flows through that heat exchanger,
without need of a storage tank to warm reach that temperature. The
construction of heat exchangers in instantaneous water heaters
should be well understood.
Fuel control valve 114 supplies fuel to the burner in response to
detection of a predetermined water flow rate through water heater
100, as sensed or measured by a flow sensor 116 operatively
disposed in water supply line 102 between the cold water inlet and
heat exchanger 110. Fuel control valve 114 may be configured to
open in response to a water flow rate greater than a predetermine
demand flow rate sensed by flow sensor 116. For example, fuel flow
control valve 114 may be controlled by a controller 113 operatively
coupled to flow sensor 116 so that controller 113 receives a signal
from flow sensor 116 indicating the rate of flow through water
input line 102. Where flow sensor 116 is a flow switch having a
binary output that changes state as flow rate moves above or below
a threshold to which the switch is set, the signal to controller
113 conveys simply whether flow through input line 102 is at or
above the threshold rate, or is below the threshold rate. In other
configurations, the flow sensor output varies with water flow rate
through input 102 so that the sensor output signal conveys specific
flow rate data. In the latter arrangement, controller 113 receives
the signal and compares the flow rate indicated thereby to a
predetermined flow rate threshold. If the controller determines
that the flow rate indicated by flow sensor 116 is greater than the
predetermined demand flow rate, controller 113 sends a control
signal to fuel control valve 114, e.g. via a suitable relay,
causing valve 114 to open. That is, control valve 114 opens in
response to receipt of a flow sensor signal indicating that the
water flow rate satisfies, e.g. exceeds, the predetermined demand
flow rate. Opening of the fuel control valve 114 supplies fuel from
fuel input line 112 to burner 106 for combustion in conjunction
with simultaneous activation of an igniter (not shown) at a burner
surface, thus activating burner 106. The igniter is also controlled
by a signal from controller 113 via circuitry that connects the
igniter with an electrical power source, as should be understood.
Moreover, the control and ignition of fuel to burners of
instantaneous water heaters should be understood.
In other embodiments, in which flow sensor 116 is a binary flow
switch, the switch outputs a signal in either of two states. When
water flow through input line 102 is below a predetermined
threshold level defined by the construction or setting of switch,
switch is in a first state, as reflected by its output signal to
controller 113. When the output signal is in this first state,
controller 113 maintains burner 106 in an inactive condition. When
water flow through input line 102 exceeds the threshold level,
switch changes state, thereby changing the state of the output
signal to the controller 113, which in turn causes the controller
113 to actuate burner 106 as described above.
In some example embodiments, the water heater may also include a
temperature sensor 124, e.g. a thermistor-based device attached to
the exterior of outletline 104. Temperature sensor 124 senses or
measures the temperature of the heated water exiting heat exchanger
110 or water heater 100 and outputs a corresponding signal to
controller 113. In response, controller 113 controls fuel control
valve 114 based on the temperature of the heated water. More
specifically, controller 113 receives temperature data indicative
of the temperature of the heated water from temperature sensor 124,
compares the indicated temperature to one or more predetermined
temperature thresholds or ranges, and controls an amount of fuel
supplied to the burner by fuel control valve 114 based on whatever
the indicated temperature satisfies the one or more temperature
thresholds or ranges. For example, if the water temperature at the
outlet water line is less than 120 degrees Fahrenheit, controller
113 modifies the control signal to the fuel control valve to supply
fuel at a 100 percent flow rate. However, if the temperature data
indicates a water temperature greater than 120 degrees Fahrenheit,
or e.g. greater than 130 degrees Fahrenheit, the controller
modifies the control signal to cause the fuel control valve to
limit the fuel flow rate to 50 percent or 25 percent, respectively.
Multiple temperature thresholds may allow for greater heated water
temperature regulation by water heater 100.
In some embodiments, water heater 100 includes a bypass flow line
122 that is operably coupled, i.e. fluidly connected, between cold
water supply line 102 and hot water outlet line 104. Bypass flow
line 122 allows flow of cold water between water supply line 102
and hot water outlet 104, bypassing heat exchanger 110. Flow sensor
116 is disposed upstream of the bypass, such that flow sensor 116
senses or measures water flow through the water heater as a whole,
including both the flow through bypass flow line 122 and through
heat exchanger 110. Bypass flow line 122 provides a flow path
through water heater 100 that has a resistance to water flow that
is less than the resistance to flow presented by heat exchanger
110, including warming line 108, thereby lowering the resistance to
flow seen by cold water input line 102 downstream from flow sensor
116. Because water flow rate through sensor 116 depends upon the
counterbalancing factors of water pressure in line 102 and
resistance to flow downstream from line 102, when a drop in water
pressure in line 102 occurs, the lower resistance presented by the
combination of heat exchanger 110 and bypass flow line 122 (as
compared to the flow resistance that would be seen downstream from
input line 102 by heat exchanger 110 alone, in the absence of
bypass path 122) results in a water flow rate through flow sensor
116 that is higher than the flow rate that would exist in the
absence of bypass line 122. Accordingly, bypass 122 maintains a
water flow rate through sensor 116 above the threshold water flow
rate needed to change the state of flow sensor 116 (or, if the
sensor outputs a signal corresponding directly to flow rate, above
the flow rate needed for controller 113 to determine the existence
of demand), and thereby cause flow sensor 116 to send the output
signal to controller 113 that causes controller 113 to actuate
burner 106, over a range of water pressure at cold water input line
102 lower than would occur in absence of bypass 122. That is,
bypass 122 enables the flow rate though water heater 100 to
consistently satisfy the predetermined demand threshold when
connected to a water source that experiences lower pressure
conditions than would be possible in absence of bypass 122.
In some example embodiments, such as the example depicted in FIG.
2, water heater 100 includes a bypass valve 130 configured to
control the flow of fluid through bypass flow line 122. Bypass
valve 130 is controllable by controller 113 (e.g. via a suitable
relay) to open to allow flow through bypass flow line 122 and to
shut to restrict or prevent flow through bypass flow line 122.
Water heater 100 may also include a pressure sensor 132 configured
to sense a pressure of water flowing through the water heater.
Although illustrated in FIG. 2 as being operably coupled to the
bypass line (upstream from valve 130), in other embodiments
pressure sensor 132 is operably coupled to the water supply line
102 or flow sensor 116, in any event so that pressure sensor 132
measures the pressure of the water supply line 102 and thereby the
pressure of the water source. Controller 113 receives the output
signal from the pressure sensor and compares the corresponding
pressure to a threshold pressure. If the pressure is above the
threshold, the controller maintains valve 130, and therefore bypass
122, closed. If the pressure falls below the threshold, the
controller opens the valve, and therefore the bypass, thereby
allowing the water heater to operate within a range of low pressure
conditions in which it would otherwise cease operation. Valve 130
may be, for example, a solenoid-controlled valve. Such a valve can
be a normally-open valve, such that controller 113 changes the
valve's state upon detecting that pressure in input line 102 is
above the threshold pressure, or a normally-closed valve, such that
controller 113 changes the valve's state upon detecting that
pressure in input line 102 is below the threshold pressure.
FIGS. 3-5 illustrate example water heaters including a storage
vessel 140. Water heaters 100 depicted in FIGS. 3-5 may be
substantially similar to the water heaters discussed above with
respect to FIGS. 1 and 2, except for tank 140 and, as otherwise
discussed herein, should be understood to operate similarly. In an
example embodiment, hot water outlet 104 includes storage vessel
140 and a heat exchanger outlet line 142 that conveys heated water
from heat exchanger 110 to storage vessel 140. Storage vessel 140
may be configured to store a volume of heated water, such as five
liters, seven liters, ten liters, or the like. In some example
embodiments, storage vessel 140 may be insulated, such as by foam,
fiber glass, or the like, to thereby limit thermal losses from the
heated water while being stored in storage vessel 140.
Storage vessel 140 may receive heated water from heat exchanger
outlet line 142 near the bottom of storage vessel 140. Heat
exchanger outlet 142 may further be configured to cause turbulent
flow as the heated water enters storage vessel 140 to cause
increased mixing of the heated water already stored in storage
vessel 140 with the heated water flowing into the storage vessel.
In an example embodiment, temperature sensor 124 may be operably
coupled to an exterior surface of storage vessel 140.
The storage vessel may limit or prevent temperature fluctuations of
the heated water. In an example embodiment, storage vessel 140 may
provide heated water to one or more plumbing fixtures as water
flowing through the heat exchanger is heated.
Water heater 100 may include a bypass flow line 122 disposed
between water supply line 102 and the hot water outlet 104. In the
embodiment depicted in FIG. 3, for example, bypass flow line 122 is
operably coupled to the output flow line downstream of storage
vessel 140. In the example embodiment depicted in FIG. 4, bypass
flow line 122 is operably coupled directly to storage vessel 140,
such that bypass flow line 122 discharges unheated into storage
vessel 140. Bypass flow line 122 may be operably coupled to water
supply line 102 upstream of the burner housing or to warmup line
108, which wraps around the burner housing as discussed above. In a
third embodiment (not shown), bypass line 122 fluidly couples at
its output with line 142 upstream of tank 140. In any of these
embodiments, however, water from bypass flow line 122 mixes with
the water exiting heat exchanger outlet 142 and the water in the
storage vessel 140.
In any of the embodiments in which water heater 100 includes
storage vessel 140, the water heater may also include a bypass
valve 130 and pressure sensor 132, which are configured and operate
as discussed above with respect to FIG. 2. Control valve 130 may be
disposed in bypass flow line 122, where the bypass line operably
couples to the output flow line upstream or downstream of the
storage vessel. Additionally or alternatively, bypass valve 130 may
be disposed in a bypass flow line 122 that operably couples
directly to the storage vessel 140, as depicted in FIG. 5.
Example Controller
FIG. 6 illustrates certain elements of controller 113 for use with
a water heater 100. Controller 113 may be employed, for example, as
on-board circuitry associated with the water heater. Accordingly,
some embodiments of controller 113 may be embodied wholly at a
single device or by devices in a client/server relationship.
Furthermore, it should be noted that the devices or elements
described below may not be mandatory and, thus, some may be omitted
in certain embodiments.
In an example embodiment, the controller may include or otherwise
be in communication with processing circuitry 20 that is configured
to perform data processing, application execution and other
processing and management services according to an example
embodiment of the present invention. In one embodiment, processing
circuitry 20 includes a memory 24 and a processor 22. As such,
processing circuitry 20 may be embodied as a circuit chip (e.g. an
integrated circuit chip) configured (e.g. with hardware, software
or a combination of hardware and software) to perform operations
described herein.
In an example embodiment, memory 24 may include one or more
non-transitory storage or memory devices such as, for example,
volatile and/or non-volatile memory that may be either fixed or
removable. Memory 24 may be configured to store information, data,
applications, instructions or the like for enabling the apparatus
to carry out various functions in accordance with example
embodiments of the present invention among other operational
features (including controlling the burner, operating error
notification devices, etc.). For example, memory 24 could be
configured to buffer input data for processing by processor 22.
Additionally or alternatively, memory 24 could be configured to
store instructions for execution by processor 22. As yet another
alternative, memory 24 may include one of a plurality of databases
that may store a variety of files, contents, or data sets. Among
the contents of memory 24, applications may be stored for execution
by processor 22 in order to carry out the functionality associated
with each respective application.
Processor 22 may be embodied in a number of different ways, for
example as various processing means such as a microprocessor or
other processing element, a coprocessor, a controller or various
other computing or processing devices including integrated circuits
such as, for example, an ASIC (application specific integrated
circuit), an FPGA (field programmable gate array), a hardware
accelerator, or the like. In an example embodiment, processor 22
may be configured to execute instructions stored in memory 24 or
otherwise accessible to processor 22. As such, whether configured
by hardware or software methods, or by a combination thereof,
processor 22 may represent an entity (e.g. physically embodied in
circuitry) capable of performing operations according to
embodiments of the present invention while configured accordingly.
Thus, for example, when processor 22 is embodied as an ASIC, FPGA
or the like, processor 22 may be specifically configured hardware
for conducting the operations described herein. Alternatively, as
another example, when processor 22 is embodied as an executor of
software instructions, the instructions may specifically configure
processor 22 to perform the operations described herein.
In an example embodiment, processing circuitry 20 may include or
otherwise be in communication with a temperature sensors 124.
Temperature sensors 124 may be disposed at hot water outlet 104,
storage vessel 140, or the like. Temperature sensor 124 may be
configured to provide temperature data to processor 22 indicative
of a temperature of the heated water. Temperature sensor 124 may
include one or more of a thermistor, a thermocouple, a resistance
thermometer, or the like.
In some example embodiments, processing circuitry 20 may include or
otherwise be in communication with flow sensor 116. Flow sensor 116
may be disposed in water supply line 102 and provide processing
circuitry 20 with flow rate data indicative of the flow rate of the
water through the water heater 100. Flow sensor 116 may include one
or more of an orifice flow sensor, a venturi flow sensor, a nozzle
flow sensor, a rotameter, pitot tubes, calorimetrics, a turbine
flow sensor, a vortex flow sensor, an electromagnetic flow sensor,
a Doppler flow sensor, an ultrasonic flow sensor, a thermal flow
sensor, a Coriolis flow sensor, or the like.
In some example embodiments, processing circuitry 20 may include or
otherwise be in communication with bypass valve 130. The bypass
valve may be solenoid actuated, servo actuated, hydraulically
actuated, or the like. Bypass valve 130 may be a gate valve,
butterfly valve, proportional valve, needle valve, or the like
configured to selectively restrict or prevent flow through the
bypass flow line 122.
In some example embodiments, processing circuitry 20 may include or
otherwise be in communication with a pressure sensor 132. Pressure
sensor 132 may be disposed in water supply line 102, the bypass
line 122, or in association with bypass valve 130. Pressure sensor
132 may be configured to sense or measure the pressure of the water
supply line 102 and thereby a water source. Pressure sensor 132 may
include a force collector sensor, such as a piezoresistive strain
gauge, a capacitive sensor, an electromagnetic sensor, a
piezoelectric sensor, an optical sensor, a potentiometric sensor or
the like. Additionally or alternatively, pressure sensor 132 may
include a resonant sensor, thermal sensor, or ionization sensor, or
the like.
Example Flowchart(s) and Operations
FIG. 7 provides a flowchart illustrating an example method for
controlling a water heater according to an example embodiment. The
operations illustrated in and described with respect to FIG. 7 may,
for example, be performed by, with the assistance of, and/or under
the control of one or more of processor 22, memory 24, fuel control
valve 114, temperature sensor 124, pressure sensor 132, bypass
valve 130, and flow sensor 116, as described above with respect to
FIGS. 1-5. The method may include causing the heating element (e.g.
burner 106) to activate in response to the flow signal indicating
that the water flow rate through the water heater satisfies a
predetermined water flow rate threshold at operation 708.
In some embodiments, the method may include additional, optional
operations, and/or the operations described above may be modified
or augmented. Some examples of modifications, optional operations,
and augmentations are described below, as indicated by dashed
lines, such as, receiving pressure data indicative of the pressure
of the water supply line at operation 702, causing the bypass valve
to open in response to the water supply line pressure below a
predetermined pressure threshold at operation 704, and receiving a
flow signal from the flow sensor at operation 706. In some example
embodiments, the method may also include receiving temperature data
from a temperature sensor associated with the output line at
operation 710, controlling a heat output of the heating element
based on the temperature data at operation 712, and causing the
bypass valve to shut in response to the water supply line pressure
above a predetermined pressure threshold at operation 714.
FIG. 7 illustrates a flowchart of a system, method, and computer
program product according to an example embodiment. It will be
understood that each block of the flowcharts, and combinations of
blocks in the flowcharts, may be implemented by various means, such
as hardware and/or a computer program product comprising one or
more computer-readable media having computer readable program
instructions stored thereon. For example, one or more of the
procedures described herein may be embodied by computer program
instructions of a computer program product. In this regard, the
computer program product(s) that embody the procedures described
herein may be stored by, for example, memory 24 and executed by,
for example, processor 22. As will be appreciated, any such
computer program product may be loaded onto a computer or other
programmable apparatus to produce a machine, such that the computer
program product including the instructions which execute on the
computer or other programmable apparatus creates means for
implementing the functions specified in the flowchart block(s).
Further, the computer program product may comprise one or more
non-transitory computer-readable mediums on which the computer
program instructions may be stored such that the one or more
computer-readable memories can direct a computer or other
programmable device to cause a series of operations to be performed
on the computer or other programmable apparatus to produce a
computer-implemented process such that the instructions which
execute on the computer or other programmable apparatus implement
the functions specified in the flowchart block(s).
In some embodiments, the system may be further configured for
additional operations or optional modifications. In this regard, in
an example embodiment, the bypass flow line is fluidly connected
between the water supply line and the storage vessel. In some
example embodiments, the water heater also includes processing
circuitry configured to receive a flow signal from the flow sensor
and cause the heating element to activate in response to the flow
signal indicating that the water flow through the water heater
satisfies the predetermined water flow rate. In an example
embodiment, the processing circuitry is further configured to
receive temperature data from a temperature sensor associated with
the output line and control a heat output of the heating element
based on the temperature data. In some example embodiments, the
water heater also includes a bypass valve configured to control
flow in the bypass flow line. In an example embodiment, the water
heater also includes a pressure sensor associated with the water
supply line and the processing circuitry is further configured to
receive pressure data indicative of the pressure of the water
supply line and cause the bypass valve to open in response to the
water supply line pressure being below a predetermined pressure
threshold. In some example embodiments, the flow switch is disposed
in the water supply line. In an example embodiment, the bypass flow
line is operably coupled to the water supply line downstream of the
flow switch. In some example embodiments, the bypass flow line
reduces the restriction to flow between the water supply line and
the output line. In an example embodiment, the bypass flow line is
operably coupled to the outlet downstream of the storage vessel. In
some example embodiments, the storage vessel is thermally
insulated.
Many modifications and other embodiments ofthe inventions set forth
herein will come to mind to one skilled in the art to which these
inventions pertain having the benefit of the teachings presented in
the foregoing descriptions and the associated drawings. Therefore,
it is to be understood that the embodiments of the invention are
not to be limited to the specific embodiments disclosed and that
modifications and other embodiments are intended to be included
within the scope of the invention. Moreover, although the foregoing
descriptions and the associated drawings describe example
embodiments in the context of certain example combinations of
elements and/or functions, it should be appreciated that different
combinations of elements and/or functions may be provided by
alternative embodiments without departing from the scope of the
invention. In this regard, for example, different combinations of
elements and/or functions than those explicitly described above are
also contemplated within the scope of the invention. Although
specific terms are employed herein, they are used in a generic and
descriptive sense only and not for purposes of limitation.
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